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Cryomodule SPL

Cryomodule SPL. Vacuum Vessel and Assembly Tooling. Sébastien ROUSSELOT Patricia DUCHESNE Philippe DAMBRE Patxi DUTHIL Denis REYNET . SPL Cryomodule Conceptual Design Review. CONTENTS. Introduction Cryostat Overview The short cryomodule design strategy

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Cryomodule SPL

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  1. Cryomodule SPL Vacuum Vessel and AssemblyTooling • Sébastien ROUSSELOT • Patricia DUCHESNE • Philippe DAMBRE Patxi DUTHIL Denis REYNET SPL CryomoduleConceptual Design Review Unité mixte de recherche CNRS-IN2P3 Université Paris-Sud 1191406 Orsay cedex Tél. : +33 1 69 15 73 40 Fax : +33 1 69 15 64 70 http://ipnweb.in2p3.fr

  2. CONTENTS Introduction Cryostat Overview The short cryomodule design strategy Vacuum vessel and tooling design aspects Vacuum vessel and coupler interface The supporting system concept Alignement requirements Coupler compensation interface with the vacuum vessel Vacuum Vessel design Constraints Requirements Different concepts ConceptualCryostatingTooling Mobile Frame Tooling mobile Trolley Tooling Cantilever tooling vertical cryostating Tooling Comparison of cryostatingtoolings Removable Top Cover Vacuum Vessel Generaldimensions Computations of differentloadings Construction aspects Farication Aspects Conclusion

  3. Introduction Cryostat overview Goal Design and construct a ½-lenght cryomodule for the test of 4 β=1 cavities (instead of 8 in a machine type cryomodule) in conditions as close as possible to a machine-type cryomodule Cryostat specific main objectives Learning of the critical assembly phases: From clean room assembly of cavities to a cryomodule Alignment/assembly procedure Proof of concept of “2-in-1” RF coupler/cavity supporting: Fully integrated RF coupler: assembly constraints Active cooling effect on cavity alignment Operation issues: Cool-down/warm-up transients, thermo-mechanics, heat loads Alignment/position stability of cavities Cryogenic operations (He filling, level controls, RF coupler support tube cooling)

  4. Introduction Vacuum vessel and tooling design aspects The short cryomodule design strategy Technical solutions focus on the ½-lentgh cryomodule Technical solutions were developed for the full length cryomodule (more constraining environment) Specifically the tooling for the cryostating • Mechanical design • Cryogenics (Heat loads, T and P profiles, segmented machine layout) • Designed for 0%-2% test (for 1.7% expected tunnel slope) 4 cavities less

  5. Vacuum vessel / coupler interface Intercavity supports The supporting system concept The RF coupler (its double-walled tube) provides: fixed point for each cavity (thermal contractions) mechanical supporting of each cavity on the vacuum vessel The intercavity support provides: a 2nd vertical support to each cavity (limits vertical self-weight sag) relative sliding between adjacent cavities along the beam axis enhancement of the transverse stiffness to the string of cavity (increases the eigenfrequencies of first modes) RF coupler double-walled tube flangefixed to vacuum vessel

  6. Vacuum vessel / coupler interface Alignement requirements • Budget of tolerances : • GeometricalTolerances of the assembly: • Cavity/He Vessel /Coupler/Vacuum Vessel ΔXY= 1.48mm / ΔZ= 3,5mm ± 1.48 mm For eachcavity, compensator component on the coupler side • To compensate the assemblytolerances (longitudinaly and angulary) • Enable to support the cavitieswithoutloosing the alignment (fixed point) Z 3.5 mm Y X

  7. Vacuum vessel / coupler interface Coupler compensation interface with the vacuum vessel Principle scheme Beam Axis Cavity Vacuum Vessel Double Wall Tube Seal Coupler Body Adjustable Fixation Adjustable Fixation Bellow

  8. Vacuum vessel / coupler interface Coupler compensation interface with the vacuum vessel Chosen solution Horizontal blocking system Fixation Flange Seal Stud M10x1 Screw SphericalWashers Bellow nuts Intermediateflange Double-wall tubeLowerflange The detailed study of this interface has been done. It will soon be constructed and tested on a mock-up by CERN. Note technique : NT-21B-004 Conception des paliers supports

  9. Vacuum vessel / coupler interface Assembly procedure Coupler compensation interface with the vacuum vessel • Vacuum vessel lift of • Contact of the 4 coupler sealing flanges to the 4 bearings of the vacuum vessel • And fixing • defaults located at the level of the 4 bearing plans are compensated by the flexibility of the bellows.

  10. Vacuum vessel / coupler interface Assembly procedure Coupler compensation interface with the vacuum vessel Fixation of the coupler flange Lower curved washers and nuts are put in contact to the coupler flange and blocked. Upper nuts can be clamped . X,Y adjustable stops are blocked.  No motion is allowed between the coupler flange and the vacuum vessel bearing (translation nor rotation).

  11. Vacuum Vessel design Constraints • Constraints due to the assembly method of the string of cavities • Pre-Alignment in the clean room required (interconnection bellows) • Cavities cleaned and filled with nitrogen (1020mbar)  2 x valves minimum ≈6000 Impact on the vacuum vessel global size ≈7000

  12. Vacuum Vessel design Constraints • Constraints due to the supporting System: • Cavities supported and fixed by the lower flange of the double-wall tube of the coupler • Size of the power coupler • Size of the vacuum gauje minimum 1130 Outer part of the coupler disassembled Impact on the vacuum vessel global size Ø480 Ø1200 min 246 Coupler Bearing Ports Ø600

  13. Vacuum vessel design Requirements Maintenance aspects : Access to the tuner, the HOM, withoutdecryostating Maintenance access ports Bearing Ports

  14. Vacuum Vessel design Different concepts Cylindrical vacuum vessel (LHC type) • Vacuum vesselwith longitudinal aperture • Bottom cover • Top cover

  15. Vacuum Vessel concepts Removable bottom cover vacuum vessel Different concepts Sealing interface Reference plane ( Great stiffnessrequired) Those two functionalities are here difficult to achieve (tight tolerances required during construction)

  16. Vacuum Vessel concepts Removable top cover vacuum vessel Differentconcepts Sealing interface (flexibility) Reference plane ( Large stiffnessrequired)

  17. ConceptualCryostatingTooling • Horizontal cryostating • Vertical Cryostating

  18. ConceptualCryostatingTooling • Horizontal cryostatingToolingStudies Mobile Frame tooling Mobile Trolley Tooling Cantilever Tooling • Vertical CryostatingToolingStudy Vertical CryostatingTooling

  19. ConceptualCryostatingTooling Mobile frame tooling • Translation of the string • + • Beamstraightness • + • Beams twist Mobile frame and string of cavities Vacuum Vessel Referencebeampath Beamsupporting structure (through the vessel) • Probable lost of alignment during translation Lifting columns Dressing and alignment Stand Cryostating Stand

  20. ConceptualCryostatingTooling Reference plane: Thermal Shield Mobile trolley tooling • Translation of the string • + • Rolling way into the thermal shield • + • Rolling way on the ground String of cavities SupportingBeams V.Vessel-T.Shieldassembly Stand Thermal Shield Reference plane: ground Front Trolley Thermal Shield Support frame Cryostatingbeams Rear Trolley Vacuum Vessel • Probable loss of alignment during translation Vacuum Vessel Ø1200mm min Cryostating Stand String of Cavities

  21. ConceptualCryostatingTooling Cantilever tooling • Translation of the Vacuum Vessel Vacuum Vessel Cantilever beam No Loss of alignment • Beamdeflection ~ 50mm • + • Beam size  no spacearroundcavities Lifting Trolleys • 1 loadtransferbetween the alignment and cryostating stands • De-cryostatingverydifficult

  22. ConceptualCryostatingTooling Vertical cryostating tooling • Vertical Translation of the Vacuum Vessel Vacuum Vessel No Loss of alignment • Top Opened Vacuum Vessel Transport,dressing and alignment frame Lifting columns

  23. ConceptualCryostatingTooling Comparison of cryostatingtoolings

  24. Removable Top Cover Vacuum Vessel General dimensions 1054 Smallerdiameter  Easier maintenance access 1021 7400

  25. Removable Top Cover Vacuum Vessel Proposed Top coverprinciple Pairs of half rings partiallywelded stiffness Weldseam Area not welded  Flexibility of the top coversealing zone

  26. Removable Top Cover Vacuum Vessel Top coversealing • Sealing (prototype): • Polymersealplaced in a groove made in the flange of the vessel main part. • Screwswillprovidesufficientdeflection of the cover for the seal compression. • (they are not used to contribute to the vacuum vesselstrength) Sealingflange This solution maybe "easily" replaced by a sealingweld, makingweldinglips on the vesselflange and on the top cover

  27. Removable Top Cover Vacuum Vessel Top cover contribution to the vacuum vesselresistance Top ring Pin Washer Bottom ring Screw (used for the lockingonly)

  28. Removable Top Cover Vacuum Vessel Computations of different loadings Top rings Top cover (6mm) Screws … Sealingflange Bottom rings Vessel (10mm) Modelisation of the interfaces : Top ring Top coverwall Fixation of the rings : In red : Sliding contact interfaces withm = 0 in fixation area pin Sliding contact interface cover / sealingflangewithm = 0 washer Sealingflange Plates Vesselwall screw Bottom ring

  29. Removable Top Cover Vacuum Vessel Computations of different loadings Other links : Weldseamsbetween rings and cover Mergedmeshingbetweensealingflange and vessel 2 Rigid bodies for fixation X, Y, Z of the second foot Rigid body for applying the efforts induced by the string of cavities Weldseamsbetween rings and vessel Rigid body for fixation X, Y, Z of the first foot Mergedmeshingbetween fixation flange of copler and vessel • Simulatedloadings : • Gravity • External pressure • Handling • Buckling Meshing :

  30. Removable Top Cover Vacuum Vessel Loading: weight (string of cavities + vacuum vessel) Open vessel Displacement in Z axis of eachbearing (mm) : Z Results in configuration Open vesselwithcavities : Maximum stress = 22 MPa Maximum deflection = 0.13mm

  31. Removable Top Cover Vacuum Vessel Loading: weight (string of cavities + vacuum vessel) Closedvessel Displacement in Z axis of eachbearing (mm) : Z Results in configuration Closedvesselwithcavities : Maximum stress = 24 MPa Maximum deflection = 0.11mm

  32. Removable Top Cover Vacuum Vessel Loading: external pressure of 1 bar (vacuum simulation) Displacement in Z axis of eachbearing (mm) : Z Results in configuration Gravity + external pressure : Maximum stress = 260 MPa (washers) Maximum deflection = 0.65mm Maximum stress = 120 Mpa (vessel)

  33. Removable Top Cover Vacuum Vessel Loading: external pressure of 1 bar (vacuum simulation) Results in configuration Gravity + external pressure : Von Mises stresses : VESSEL : Max stress = 120 MPa(traction) PLATES: Max stress = 130 MPa(traction) RINGS : Max stress = 110 MPa(traction) WASHERS : Max stress = 260 MPa(compression) Shape x20 Sliding of the top cover : Contact force on the sealingflange : Max sliding = 0.65mm Contact is maintained all around the flange

  34. Removable Top Cover Vacuum Vessel vacuum simulation Whysomany rings ? Maximum deflection = 2.48mm Maximum deflection = 0.65mm Max slidingbetweencover and flange = 0.65mm Max slidingbetweencover and flange = 2.4mm Washers : 500 Mpa Vessel : 250 MPa Plates : 350 Mpa Rings : 320 Mpa Cover : 143 MPa Washers : 260 Mpa Vessel : 110 MPa Plates : 130 Mpa Rings : 110 Mpa Cover : 68 MPa Maximum stresses : Maximum stresses : • High local stresses • Significantslidingbetweencover and flange

  35. Removable Top Cover Vacuum Vessel Uz = 0 Handling Handling via supports between rings Case 5 : Uy = 0 Uz = 0 Ux = 0 Uz = 0 z y x Case 5 : Ux = 0 Uy = 0 Uz = 0

  36. Removable Top Cover Vacuum Vessel • Mode 1 : 3.91 ( Critical pressure : 0.39 MPa) Buckling • Hypothesis for buckling simulation : • No contact betweencover and vessel • No screwbetweencover and vessel Mode 2 : 3.93 Computation of the first 20 buckling modes : Only local buckling modes on the cover No global buckling mode founduntil a min critical value of 1MPa. Areas of the local buckling modes • Hypothesis for buckling simulation : • Nodes are linkedbetween the cover and the vessel • Mode 1 : 42 ( Critical pressure : 4.2 MPa)

  37. Removable Top Cover Vacuum Vessel Fabrication aspects A company was consulted to verify the possibility (and cost) of constructing this vacuum vessel. NB: The company (CMI) is currently in charge of 3 vacuum vessels (being 9, 10 and 11m length) for the triplets update of the LHC. Vacuum vesselwith a top openingseemsfeasible.

  38. CONCLUSION Coupler / vacuum vessel interface An interface was designed: compensating the coupler flange position tolerances; supporting the mass of the string of cavities; insuring the sealing of the vacuum vessel bearings. This interface will be tested on a mock up at CERN.

  39. CONCLUSION Vacuum vessel A vacuum vessel with a top opening and a top cover is proposed. It may allow: the vertical cryostating of the string of cavities by use of a dedicated tooling which was conceptually studied providing the better probability of keeping the alignment of the string of cavities during cryostating making easier the alignment diagnostic within the vacuum vessel The proposed top cover combines high stiffness and flexible behaviors for the purpose of bringing together sufficient mechanical strength and a dismountable tight interface. Preliminary computations exposes that this vacuum vessel may be sufficiently strength to induce on the one hand small deflections of the bearings interfaces during vacuum, handling and, one the other hand, to buckling. Finally a preliminary consultation with a company have indicated that this vessel could be constructed (at a cost a bit more important than a cylindrical vacuum vessel)

  40. Thank you for your attention Unité mixte de recherche CNRS-IN2P3 Université Paris-Sud 1191406 Orsay cedex Tél. : +33 1 69 15 73 40 Fax : +33 1 69 15 64 70 http://ipnweb.in2p3.fr

  41. Removable Top Cover Vacuum Vessel Fabrication aspects

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